Carton



July 26, 1960 Filed May 14, 1957 A. E. RANDLES, JR 2,946,497

CARTON 3 SheetsSheet l INVENTOR. ARTHUR E HANDLES, JR.

ATTORNEYS July 26, 1960 Filed May 14, 1957 A. E. RANDLES, JR 2,946,497

CARTON 3 Sheets-Sheet 2 rlol I02 5 10: h IOI \111 \1 I INVENTOR. ARTHUR E. HANDLES, JR.

sYl w piLk ATTORNEYS July 26, 1960 A. E. RANDLES, JR 2,946,497

CARTON Filed May 14, 1957 3 Sheets-Sheet 5 mm LQXf E k INVENTOR.

ARTHUR 5 RANDL ES, JR.

ATTORNEYS United States Patent M CARTON Arthur E. Randles, Jr., Redwood City, Calif., assignor of one-half to Fred E. Helmick, Menlo Park, Calif.

Filed May 14, 1957, Ser. No. 659,044

1 Claim. (Cl. 229-28) 7 The invention relates to improvements in collapsible cellular cartons and, more particularly, to cartons of the kind widely used to package eggs and comparably shaped fragile objects.

One of the major losses in the chain of distribution of eggs, and other fragile items, ts that occasioned by breakage. Especially where eggs are involved, breakage of even one egg in a carton often entails the re-packaging and down-grading of eggs located in subjacent cartons, this particularly being true in present-day cartons having apertures in the bottoms adjacents the outer edges. The contents of the broken egg, in other words, flow through the apertures, as located in currently used cartons and spill onto the carton or cartons below, making re-pack-ag ing necessary.

Breakage ordinarily occurs because of the concentration of weight of overlying cartons on one or more eggs in subjacent cartons, the concentration being caused by improper orientation of an egg in its compartment or by an eggs being oversize and thus bearing the thrust of the weight above it. To circumvent this situation it has been necessary to keep the carton stacks to a small height even though such stacking isoften an ineificient utilization of space.

It is therefore an object of the invention to provide an egg carton in which breakage is substantially eliminated.

It is another object of the invention to provide an egg carton which can be stacked to a height substantially greater than that permitted with presently used cartons. It is yet another object of the invention to provide an egg carton in which pairs of eggs in transversely adjacent compartments are held apart by resilient walls each spaced from the other, so as to provide maximum protection against breakage resulting from lateral forces.

It is still another object of the invention to provide an egg carton which is relatively economical to make and is susceptible of quick erection by automatic machinery.

It is yet another object of the invention to provide an egg carton which lends itself to ease of stacking.

I It is a further object of the invention to provide an egg carton whose blank can be cut in one piece and which does not require a separate glue strip.

It is still a further object of the invention to provide an egg carton whose blank makes maximum utilization of the paper stock.

It is yet a further object of the invention to provide an egg carton in which the carton cover is not only supported on its opposite edges but along its longitudinal centerline as well.

'It is yet another object of the invention to provide an egg carton in which the gravital thrust of a stack of car tons is exerted directly downwardly through a succession of central rib members in such a fashion that weight concentration on particular eggs is substantially eliminated;

It is a yet further object of the invention to provide an egg carton in which the fluid from an egg, if broken, is largely, if not entirely, confined to the carton, and,

2,946,497 Patented July 26, 1960 therefore, does not flow downwardly so as to damage the subjacent cartons.

It is another object of the invention to provide a generally improved egg carton.

Otherobjects, together with the foregoing, are attained in the embodiment described in thefollowing description and shown in the accompanying drawings in which:

Figure 1 is a perspective of the egg carton of the invention, the cover being shown in open position;

Figure 2 is a plan of the carton shown in Figure 1;

Figure 3 is an end view, the cover being shown in closed, or locked position;

Figure 4 is a section to an enlarged scale, the plane of section being indicated by the line 4-4 in Figure 2;

Figure 5 is an end view of the carton in a stage of partial assembly, the view emphasizing the rigid structure of the center rib, or truss member;

Figure 6 is a plan of the blank from which the carton is constructed.

While the carton of the invention is susceptible of numerous physical embodiments depending upon the environment and requirements of use, a considerable number of the herein shown and described embodiment has been made and used and has performed in an eminently satisfactory manner.

The carton of the invention, generally designated by the numeral 11, resembles the customary dozen-egg capacity carton in that it comprises an elongated box-like body 12 bounded on opposite sides by a high wall 13, or cover carrying wall, and a low wall 14, or cover locking wall.

A cover 15 is foldably connected to the upper edge 16 of the high wall 13 and is swingable about a fold line 17. Likewise foldable about a scored line 18 adjacent the distal end of the cover 15 is a locking flap 19, the flap 19 being provided with a plurality of hooks 21 adapted latchably to engage with a plurality of triangular shaped gus- ,sets 22, or hinges, extending inwardly, at longitudinally .spaced intervals, from the upper margin23 of the low wall 14.

Dividing the box into a longitudinal series of compartments is a plurality of transverse partitions 31, each of the partitions being substantially identical to the other except that the opposite end partitions 32 differ from" the interior partitions in a small but important fashion. Whereas the lower outermost corners 36 of the end partitions 32' are trimmed or clipped but a small amount, if at all, the corresponding corners of the interior partitions are clipped to a significant extent, as indicated by the numeral 38, and shown most clearly in Figures 3 and 6. The purpose in treating the interior partitions as indicated is that in the event an egg were to break, the fluid from the egg is enabled readily to flow along the outermost bottom corners 41 and 42 of the walls 13 and 14, respectively, without hindrance from intervening partitions. Upon coming against either of the end partitions 32, however, the smallness of the clipped portion effectively prevents further movement of the fluid. In other words, the different treatment ac corded the partitions encourages free longitudinal flow within the box but entrapment adjacent each end.

The reason, in turn, why free longitudinal flow along the inner corners 41 and 42 is permitted, and encouraged, is that, unlike mostegg cartons heretofore used, each of 5 the bottom panels 43 and 44 is uninterrupted by any apertures for a substantial portion of its dimension measured inwardly from the respective corners 41 and 42 toward the inner corners 46 and 47, or knees, respectively, of the bottom panels. As appears most clearly in Figure 2, the distance between the corner 41, for example,

and the imaginary longitudinalenvelope line, designated 48, defining the outermost boundaries of the bottom panel aperturcs 49 is substantial, the distance being approximately three-fourths of the total bottom panel dimension measured between the corner 41 and the knee 46. As a consequence of this arrangement and owing as well to the upward and inward slope of each of the bottom panels, the fluid from a broken egg in any particular compartment does not overflow and spill downwardly through the aperture49 onto the subjacent carton; instead, the fluid moves longitudinally, ordinarily dividing with portions flowing toward opposite ends of the carton. The generous channels or orifices provided at the outer corners of the interior partitions encourages this longitudinal flow. Upon encountering an end partition, however, additional endwise flow is halted. The fluid, in other words, is trapped within the carton, the harm confined to the carton itself.

' As can be seen most clearly by reference to Figures 1, 2 and 6, each of the transverse partitions, including the end partitions 32, originally forming part of a partition panel 50 and on one side is hingeably secured to the triangular hinge 22, or locking gusset, the fold line being indicated by the numeral 51, and on the other side is foldably mounted on a corresponding hinge 52, or gusset, the scored fold line being designated by the numeral 53. Each of the hinges 52 is foldably mounted, about a scored line 56, on an elongated member termed an attaching strip 57, or glue strip, the member 57 having been secured firmly to the high wall, at its appropriate location, prior to erection of the carton.

It will be noted, incidentally, by reference to Figure 6, that the glue strip 57 is indicated as having disposed thereon an adhesive 58, for example, an adhesive of the pressure-sensitive type. Prior to erection, approximately the lower third of the blank, as it appears in Figure 6, is folded upwardly about an interrupted score line or fold axis generally designated by the numeral 61. This folding operation locates the bottom margin 62 of the glue strip in the location indicated in outline and designated by the numeral 63, such location being the correct one as subsequent erection of the carton is efiected.

.As appears most clearly in Figures 1 and 3, each of the partitions is symmetrical about a median vertical axis 66, or median longitudinal plane. The lower edges 67 of the partition are carefully cut so as to conform with the slope of the corresponding bottom panels 43 and 44 and the upper edges 68 slope upwardly and inwardly to form a peak 69 touching the adjacent lower surface of the cover 15 in closed position thereof. A pair of notches 70 is created by virtue of the folding of the partition at right anglesto the adjacent horizontal triangular hinges 22 and 52. Adjacent each of the notches 70 is a tip portion 71 added somewhat to the beam, strength adjacent the upper edges 68 of the partition.

symmetrically disposed in the central portion of each of the partitions is an upper isolated notch 76, or aperture whose shape appears most clearly in Figure 6, the aperture con-forming in shape to a truncated isosceles triangle, and being bounded by an upper wall 77, paral lel lower wall 78 and a pair of inclined side walls 79.

Co-linear with each of the side walls 79 is a pair of inclined boundary walls 81 of a lower and generally truncated triangular notch 82, the upper wall 83 of the notch 82 'being parallel to and spaced from the adjacent notch wall 78, a band 84 separating the two walls.

The foregoing notches or apertures 76 and 82 as well as the intermediate band 84 serve, in conjunction with cooperating elements in a longitudinally disposed rib member, generally designated by the numeral 91, to hold the transverse partitions in firm vertical attitude.

The rib member acts, however, not only as a partition securing element but also as a brace or strut or truss member serving to support the cover 15 against the downward thrust of superposed cartons and totransmit this weight onto subjacent cartons in elficiently distributed fashion. This is to say, that the weight impressed on the strong, stifl? apex 92 of the triangular or inverted V-shaped rib panels 93 and 94 is passed down each of the panels 93 and 94 and is in turn, transmitted to supporting tabs 96 and 97 terminating in lower edges 98 and 99, respectively, which are co-terminous or coplanar with respect to the corner edges 41 and 42 of the carton. The carton weight is consequently divided between the corners 41 and 42 and between the tab edges 98 and 99, any severe concentration of thrust being thereby avoided.

Preferably, each of the interior supporting tabs is somewhat stubby to provide the required beam strength and resistance to bending or buckling. The two end tabs 1%, on the other hand, are ordinarily modified to some degree to reflect the reduced thrust condition there obtaining. Stiffness of the supporting tabs is augmented by provision of substantial root lines 101, the tabs tapering downwardly, in converging fashion, from the opposite ends 102 of the root portions 101 along a pair of tab edges 103 to the bottom edge 99, as appears most clearly in Figure 4.

The tabs are cut from a portion of the material forming the bottom panels of the carton. Cuts or slits in the blank are suitably provided so that when the carton is erected and the tabs are disposed in their normal or extended attitude, the plurality of correspondingly configured apertures 49 in the bottom panels are created, the apertures 49 having previously been mentioned in connection with the flow of fluid from a broken egg, it having been stated that since the apertures 49 are located very close to the central rib, and also at an elevated position, the likelihood of escape of fluid through the apertures 49 is extremely small.

Cooperating with the transverse partition elements and serving to lock the transverse partitions in a secure fashion is a plurality of cuts and notches in the material symmetrically disposed around the longitudinal median axis or plane 66. A plurality of interior triangular apertures 111 form, when the opposite rib panels 93 and 94 are folded into triangular contour, a registering pair of triangular notches 112, as appears most clearly in Figure 4. Each of the notches includes a sloping wall 113, or edge, and a vertical edge 114, the vertical edge serving to brace or support the adjacent portion of the transverse partition. Continuing the line of each of the edges 113 is a cut 116, the cut 116 opening as carton erection takes place and permitting the passage through the cut of the band 84. As soon as the band 84 completes the traverse through the cut, the inherent resiliency of the material causes the band to snap to the vertical attitude shown most clearly in Figure 4, the band then underlying a triangular tip 117 created by a roughly rectangular opening 121, the opening 121 being bounded by an upper edge 122, a lower edge 123, and a vertical side edge 124.

With especial reference to Figures 3 and 4, it can be seen that the vertical dimension of the edge 124 is such that the cross-band 84 is securely confined and is maintained in vertical attitude and is restrained against vertical movement, the ledge 122 of the tip resisting upward motion. The cam or slope of the wall 123, furthermore, urges the band into face to face abutment with the vertical wall 124.

The vertical dimension of the opening 76 in the parti-' tion is such that the tip 117 fits in rather snug relation, as can be seen most clearly in Figure 4, this interlock serving, along with the abutment between the band 84 and its confining members, securely to position both the rib panels and the transverse partition. In sum, the rib panels lock the partitions, and the partitions the panels, the overall effect being to produce a carton of very great strength not only againstvertical thrusts but horizontal or lateral forces as well.

It is sometimes found advisable, for convenience in erection, that notches 131 in the upper corners of the rib panels adjacent the partitions be provided.

A slightly difierent treatment of the rib notches is atforded in the case of the end notches 132, where, as appears in Figures 4 and 6, the end partition is disposed approximately half way between the edges 133 and 134 of the notch 132. This structure lends itself to ease of assembly and in no way detracts significantly from the strength since at each end there is no thrust longitudinally from the end of the box, there being no egg compartments, obviously, outside the end partitions.

In addition to its outstanding rigidity, the carton of the invention lends itself admirably to convenience in storage and assembly. As previously stated, with the lower onethird, approximately, of the carton having been folded so that the edge 62 of the glue strip 57 is located at the line 63, only two thicknesses of the material are involved. This is to be contrasted with the several thicknesses encountered in many of the presently used, partially assembled cartons. As a consequence of there being only two thicknesses, the flat cartons can be easily stored and shipped and, in addition, can be erected with great facility and speed, and are therefore especially adaptable for use with high speed automatic machinery.

In forming the erected box shown in Figure 1 from the single, die-cut sheet illustrated in Figure 6, the lower margin 62 is folded upwardly, about the fold line 61, to coincide with the line 63. Adhesion of the glue strip 58 is thereupon efiected. Next, the combined high wall 13 and the bottom panel 43, the combined rib panels 93 and 94, the combined bottom panel 44 and the low wall 14, and the partition panel comprising the seven partitions and the hinges, or gussets, are folded into substantially square hollow box form. This operation, as well as the succeeding steps of downturning the individual partitions into transverse attitude and of urging the triangular rib structure upwardly into engagement with the transverse partitions and the concurrent folding of the bottom panels 43 and 44 is preferably accomplished by high speed machinery of the kind shown and described, for example, in my co-pending application, Serial No. 729,448, filed April 18, 1958, for Carton Forming Machine. After interlocking of the tn'angular rib and the transverse partitions, the carton assumes substantially the form shown in Figure 1 and is prepared to be loaded with eggs, followed by closure and locking of the cover as appears in Figure 3.

I claim:

An egg carton comprising a single sheet of fibreboard material when erected and closed having a planar horizontal cover panel connected along a rear edge fold to a substantially vertical rear panel extending to a first bottom edge in a horizontal plane, said cover being disposed along its front edge at the upper edge of a substantially vertical front panel extending to a second bottom edge in said horizontal plane, a securing strip on said rear panel adjacent said rear edge fold, connectors extending from said upper edge of said front panel and from said securing strip, substantially vertical cross partitions depending from said connectors and extending transversely between said front panel and said rear panel, each of said cross partitions having a front edge and a rear edge and having a notch extending upwardly from the bottom thereof and having an opening with a bottom edge located above said notch, the forward edges of said notch and of said opening being in a first straight line and the rearward edges of said notch and of said opening being in a second straight line, said first line and said second line diverging downwardly from a point substantially in the plane of said cover panel, a pair of downwardly diverging planar central panels each lying substantially along a respective one of said lines and extending substantially from a fold substantially at said point to terminations in said horizontal plane, said central panels having cutouts to accommodate said cross partitions, books on said central panels extending into said opening and having bottom edges engaging said bottom edge of said opening, a first bottom panel connected to said front panel and merging with one of said central panels above the bottom thereof, and a second bottom panel connected to said rear panel and merging with the other of said central panels above the bottomthereof, the transverse dimension of said first bottom panel being substantially the same as that of the adjacent bottom edge of the cross partition between the front edge thereof and the forward edge of said notch and the transverse dimension of said second bottom panel being substantially the same as that of the adjacent bottom edge of the cross partition between the rear edge thereof and the rearward edge of said notch whereby said central panels are increasingly spaced apart from top to bottom of said carton and are held in diverging locations against the diverging front and rear edges of said opening and of said notch.

References Cited in the file of this patent UNITED STATES PATENTS 1,977,427 Burger Oct. 16, 1934 2,091,960 Brundin Sept. 7, 1937 2,106,613 Levkofl? Jan. 25, 1938 2,340,753 Inman Feb. 1, 1944 2,387,314 Cox Oct. 23, 1945 2,803,392 Bemiss V Aug. 20, 1957 

